Composite Lattice Bars for Early Rupture Warning
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Solution Overview
Problem
Composite structural parts made of fiber-reinforced thermoplastic or thermosetting matrix are prone to failure without visible signs of damage, necessitating significant oversizing to prevent breakage, which is undesirable in terms of weight and cost.
Innovation Solution
Integrate a lattice structure with fibers arranged to form bars that are calibrated to fail at a predetermined stress level lower than the maximum stress, incorporating sensors to detect this failure and emit a signal, allowing for preventive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If composite parts are oversized to prevent breakage and withstand fatigue loads, then reliability is improved, but weight and cost increase
Solution Approach 1:
The patent implements a warning system that performs preliminary detection of damage and stress accumulation before catastrophic failure occurs. Sensors monitor the composite part continuously and trigger warnings when damage thresholds are reached, enabling preventive action before the part fails, thus allowing optimization of part sizing without compromising safety
Solution Approach 2:
The patent employs a feedback mechanism where sensors detect the state of the composite part (damage, stress levels) and provide continuous information to a monitoring system. This feedback loop allows real-time assessment of part integrity and enables dynamic adjustment of operational parameters or maintenance scheduling, replacing the need for conservative oversizing
2Reliability
If composite parts are oversized to ensure integrity after damage, then reliability is improved, but weight and cost increase
Solution Approach 1:
The patent divides the monitoring function into discrete sensor units distributed throughout the composite part structure. Each sensor monitors a specific local region for damage or stress, and the system integrates these segmented measurements to assess overall part integrity. This modular approach enables targeted monitoring without requiring excessive redundancy
Solution Approach 2:
The composite part incorporates self-monitoring capabilities through embedded sensors that automatically detect damage and stress conditions. The system serves itself by providing real-time information about its own integrity state, eliminating the need for external inspection systems or complex manual monitoring procedures
3Reliability
If damage detection capability is improved, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent employs sensors that perform multiple functions simultaneously - detecting both damage (delamination, fiber breakage) and stress/strain conditions. This multi-functionality reduces the total number of separate sensing systems needed, simplifying the overall monitoring architecture while maintaining comprehensive reliability assessment capabilities
Solution Approach 2:
The patent utilizes composite material structures that integrate sensing capabilities directly into the material matrix or reinforcement elements. By embedding sensors within the composite structure during manufacturing, the system achieves damage detection without adding external components, thereby improving reliability while minimizing increases in device complexity
Data Source
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AI summary
The invention relates to a method for warning of risk of rupture or deformation of a part (1) made of a composite material when it is subjected to a force, said part comprising a fibre-reinforced thermoplastic or thermohardenable matrix. Said method consists in: arranging said fibres in a lattice structure (2) produced by winding fibres to form bars (21) that join together or intersect at nodes (20); designing at least one bar (21) of said lattice and/or integrating, into the part, at least one additional bar (3) with a determined location and tensile strength; associating, with the at least one bar, inside the part, a sensor means (4) designed to detect the rupture thereof; and associating, with the sensor means (4), a means (5) for emitting, outside the part, a signal relating to the rupture.